How to Scale a Recipe for Manufacturing

Recipes rarely scale exactly as written. Food behaves differently when you move from small batches to larger production runs. Ingredients that mix easily in a five-pound batch might clump or separate in a fifty-pound batch. Heat, time, and mixing all change when the quantities increase.

The best way to learn how your recipe behaves at scale is to write everything down—every ingredient, amount, and process step. If you're part of the Union Kitchen Accelerator, you can do this in your production workbook. Documenting your process gives you a consistent baseline to test against. Without it, you’ll never know which variables are causing changes in your results.

This guide walks through how to document and scale your recipe step-by-step.

Step 1: Write Down Your Current Process

Before changing anything, write down exactly how you make your product today. Include:

• Each ingredient and its quantity

• Every action in the order you perform it

• Details like time, temperature, and mixing speed

When you record your exact process, you can reproduce your product consistently and identify where to make improvements. If your process changes every time you produce, it becomes impossible to troubleshoot or hire staff to replicate your process.

Step 2: Measure by Weight, Not Volume

When scaling up, weight (mass) is the most reliable unit of measure. Volume can change depending on density and how ingredients are packed. For example, one cup of flour might weigh differently if scooped directly from the bag or sifted first. Measuring by weight eliminates that variation.

“You will obtain better accuracy when measuring by weight… because cooking is about controlling chemical reactions based on ingredient ratios.”
— Jeff Potter, Cooking for Geeks

Step 3: Define Your Batch Size

Your batch size is the number of units produced in one production run. Keep this number constant.

Example:

If one batch produces 100 units and you receive an order for 1,000 units, you’ll run 10 batches.

Defining batch size helps you compare batches over time and ensures consistent product quality.

Step 4: Understand How Scaling Changes the Process

As batch size increases, the relationship between the surface area and volume (Sa/Vol) changes. This ratio determines how heat and mixing behave.

Because of this:

• Larger batches need longer heat exposure to reach the same internal temperature.

• Stirring and cooling take longer.

• Raising the temperature to “speed things up” can damage ingredients through oxidation or burning.

Plan for gradual adjustments in time, temperature, and mixing as you scale.

Step 5: Build a Production Plan

With your ingredients and batch size defined, outline the step-by-step plan for producing one batch. Each step should include:

• Ingredient amount

• Time

• Temperature

• Equipment used

Once listed, group your steps into categories to make the plan easier to follow and repeat:

• Ordering

• Receiving

• Storage

• Prep

• Production

• Packaging

If you're part of the Union Kitchen Accelerator, you will complete this structure in your Production Workbook—a repeatable guide for manufacturing.

Step 6: Test and Record Results

After writing your process, test each batch and record the results. Track:

• Time to complete each step

• Yield (how much finished product you get)

• Texture, flavor, and consistency

• Any issues like overheating, separation, or waste

Make one change at a time and note the result. Over time, your production workbook becomes a tested record of what works at scale.

Build with Union Kitchen

At Union Kitchen, we help founders move from small-batch recipes to full-scale production through structured systems, shared manufacturing space, and hands-on coaching.

Learn more about the Union Kitchen Accelerator and how to build your food business to last.